Method and apparatus for building a layered card

ABSTRACT

A method of processing sheet stock in the creation of plastic cards, such as gift cards or credit cards that include special effects and/or security measures. A card formed by such methods is also disclosed. The method provides for two or more dissimilar materials to be bonded together while maintaining the integrity of the card and as any graphics, security features, and/or special effects provided thereon. Thermoset and thermobond adhesive layers are placed between a first material layer and a second material layer of the sheet stock. The thermoset and thermobond adhesive layers allow the first and second material layers to move independently and to expand and contract at different rates relative to each other. The adhesive layers enable the sheet stock to be rolled up for shipping or storage and further enable the end product produced therefrom to have a planar profile.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 62/701,171, filed on Jul. 20, 2018, and U.S. Provisional ApplicationSer. No. 62/713,776, filed on Aug. 2, 2018; the disclosures of which areincorporated herein by reference.

BACKGROUND Technical Field

The present disclosure relates to a method of producing sheet stock usedin the manufacture of layered cards such as credit cards and gift cards.More particularly, the present disclosure relates to a method ofroll-to-roll processing of sheet stock in order to produce layeredcards. Specifically, the present disclosure relates to a multi-layeredcard stock and a method of producing the same where the card stockincludes aesthetic enhancements and embedded security elements and, isfabricated in such a way as to enable storage and shipping of the cardstock in a roll without adversely affecting the planar nature of thecard produced from the rolled stock.

Background Information

In the past, the creation of roll-to-roll laminations (PreLAM)comprising multiple layers, often used for the manufacture of items suchas credit and gift cards, typically uses what may be referred to as a“balanced structure”. The term “balanced structure” as used herein, isused to denote a structure where there is a front to back “mirror image”or symmetry in the product. This balanced structure used in PRIOR ARTcards typically involves assembling a card from a series of symmetricallayers, arranged as shown in FIGS. 1A-1C (and as discussed in greaterdetail layer herein). The core of these previously known cards may betermed a “split core” because the core is symmetrical about an imaginaryplane that passes through a midline of the core.

FIG. 1A shows a PRIOR ART card that includes a polyvinyl chloride(“PVC”) core that has a clear PVC front layer adjacent a front surfaceof the core and a clear PVC back layer adjacent a back surface of thecore.

In instances where embedded aesthetic effects and/or security effectsare desired, the laminates in these PRIOR ART cards are traditionallyassembled symmetrically about the split core, i.e., by preparing a firstgroup of layers that are to be applied adjacent a front surface of thesplit core and preparing a second group of layers that are to be appliedadjacent a back surface of the split core. Each of the first group oflayers and the second group of layers includes identical material layersassembled in an identical fashion but applied to the front and backsurfaces in reverse order, i.e., as mirror images of each other. Thissymmetrical production and assembly is typically undertaken to avoidinduction of manufacturing flaws into the card. The first group oflayers and second group of layers are fused together about the corelayer to form a completed card.

When it is desired for the PRIOR ART card to have a printed surface, thetraditional approach is to print directly on the PVC, i.e., on theexterior surface of the front layer and/or on the exterior surface ofthe back layer. More recently, customers have required that specialeffects such as holograms, micrograms and images, be provided on theircards. However, these special effects cannot be produced usingpreviously known “old” inks that were traditionally used to print onPVC. In an attempt to solve this problem, PRIOR ART cards have beencreated with a polyethylene terephthalate (“PET”) layer introducedbetween the core and each of the PVC front layer and the PVC back layer.PET is utilized because it is effective in holding the special effectsand graphics. PET has a very high glass transition temperature comparedto PVC, consequently, when an attempt is made to bond PVC, and PETtogether, then card so formed tends to curl. This is because the PETcools at a different rate to PVC and the PET shrinks a little as itcools, while PVC does not. To address this issue, a varnish hastypically been applied to both sides of the PET layer and then the PVClayers are bonded to the varnish. Varnish, however, often causes the PETto develop a milky or cloudy appearance and when the PVC is bonded tothe varnish, the bonding process may muddle both the ink printed on thePET and the varnish. This tends to create blemishes and defects in thefinished card. In essence, the inclusion of the varnish createspotential built-in failure layers in each card.

The inclusion of embedded security features, such as a radio-frequencyidentification chips (“RFID chips”), into the PRIOR ART cardmanufacturing process creates a separate set of problems. Previouslyknown methods of introducing RFID chips involve utilizing athermoplastic polymer that produced an off-gas during the bondingprocess. This off-gas tends to cause small bubbles to form in thefinished product, giving the card an “orange-peel” effect. This“orange-peel” effect, in turn, makes the card less aestheticallypleasing or attractive. Furthermore, the industry standard for RFIDchips with an antenna is a signal strength of approximately 13.56 MHz ina high frequency (HF) band with a read range of approximately 10 cm to 1m. According to one aspect, the HF band ranges from 3-30 MHz. However,if the signal strength of the antenna is not 10 MHz or less, thematerials used in the card tend to block the signal to and/or from thatantenna, making the card generally unusable. Prior known cards withembedded antennas therefore tend to have a failure rate of approximately40%, i.e., where the cards have become generally unreliable or unusablebecause the antenna signal is blocked.

SUMMARY

These and other objects of the present invention will be readilyapparent upon review of the following detailed description of theinvention and the accompanying drawings. These objects of the presentinvention are not exhaustive and are not to be construed as limiting thescope of the claimed invention. Further, it must be understood that noone embodiment of the present invention need include all of theaforementioned objects of the present invention. Rather, a givenembodiment may include one or none of the aforementioned objects.Accordingly, these objects are not to be used to limit the scope of theclaims of the present invention.

It should be understood that any of the terms “card”, “credit card”,“debit card”, “bank card”, “gift card”, and “identification card” may beused interchangeably in this specification. These terms are all used todenote any type of flat product that is produced from multiple layers ofmaterials, particularly plastics, that are bonded to each other and arecut to a shape and size that may be suitable to fit inside a wallet or ashirt pocket and may be used as a form of payment or identification, forexample.

Accordingly, provided are methods of processing sheet stock to be usedin the creation of a plastic card, such as a gift card or a credit cardthat may include special effects and security measures without many ofthe problems that plague current card manufacturing methods. Further,methods and designs for a card are provided, having two dissimilarmaterials bonded together while maintaining the integrity of the carditself and any graphics, security features, and/or special effectsprinted thereon or included therein.

The present disclosure may also provide a card having a non-mirror imagefront to back construction that includes a seven layers. The sevenlayers include a PVC layer, a first thermoset layer, a first thermobondlayer, a PET layer, a second thermobond layer, a second thermoset layer,and a PVC layer. The present disclosure may further provide a cardhaving an asymmetrical front to back construction where the PET layer islocated further away from a PVC front layer than from a PVC back layer.

In one aspect, the present disclosure may provide a method of processingsheet stock comprising applying a layer of a first thermoset adhesive toone side of a first material and allowing the first thermoset adhesiveto set, thereby forming a first sheet stock; applying a first layer of afirst thermobond adhesive to a first side of a second material; applyinga second layer of a second thermobond adhesive to a second side of thesecond material, and allowing the first thermobond adhesive and thesecond thermobond adhesive to set, thereby forming a second sheet stock;applying a layer of a second thermoset adhesive to one side of a secondsheet of the first material, and allowing the second thermoset adhesiveto set, thereby forming a third sheet stock; coiling one or more of thefirst sheet stock, the second sheet stock, and the third sheet stockinto a roll.

In one aspect, the present disclosure may provide a method forroll-to-roll processing sheet stock with the steps of unrolling a firstsheet of a first material from a roll and applying a first layer ofthermoset adhesive to one side thereof, thereby forming a first sheetstock; unrolling a sheet of a second material, applying a first layer ofthermobond adhesive to a first side thereof, and applying a second layerof thermobond adhesive to a second side thereof, thereby forming asecond sheet stock; unrolling a second sheet the first material andapplying a second layer of thermoset adhesive to one side thereof,thereby forming a third sheet stock; allowing each of the first andsecond layers of thermobond adhesive and first and second layers ofthermoset adhesive to set; coiling the first sheet stock into a firstroll; coiling the second sheet stock into a second roll; and coiling thethird sheet stock into a third roll.

In another aspect, the present disclosure may provide a method ofmanufacturing sheet stock comprising the steps of applying a firstadhesive layer to one side of a first material sheet; applying a secondadhesive layer to a first side of a second material sheet; applying athird adhesive layer to a second side of the second material sheet;applying a fourth adhesive layer to one side of a third material;arranging the first material sheet, second material sheet, and thirdmaterial sheet into a single stack wherein the first adhesive layer isadjacent the second adhesive layer and the third adhesive layer isadjacent the fourth adhesive layer; applying heat and pressure to thearranged stack; causing the first and second adhesive layer to mergeinto a first combined adhesive layer; causing the third and fourthadhesive layers to merge into a second combined adhesive layer; forminga single sheet stock comprising a first material layer, a first combinedadhesive layer, a second material layer, a second combined adhesivelayer and a third material layer; and coiling the single sheet stockinto a roll. The first material sheet used in this method is polyvinylchloride (PVC) the second material sheet is polyethylene terephthalate(PET); the first adhesive layer is a first thermoset adhesive, thesecond adhesive layer is a first thermobond adhesive, the third adhesivelayer is a second thermobond adhesive, and the fourth adhesive layer isa second thermoset adhesive. The first thermobond adhesive and thesecond thermobond adhesive may be the same; and the first thermosetadhesive and the second thermoset adhesive may be the same. The methodmay further comprise unrolling a length of material from the roll;cutting sections of the material from the length of material unrolledfrom the roll; and applying personal information to the cut sections.

In one aspect, the present disclosure may provide a method of building alayered card comprising unrolling a first sheet stock comprising a firstmaterial layer and a first thermoset adhesive layer; unrolling a secondsheet stock comprising a first thermobond adhesive layer, a secondmaterial layer, and a second thermobond adhesive layer; unrolling athird sheet stock comprising a second thermoset adhesive layer and athird material layer; assembling the first sheet stock, the second sheetstock, and the third sheet stock into a single stack wherein the firstsheet stock is atop the second sheet stock and the second sheet stock isatop the third sheet stock, the first thermoset adhesive layer isadjacent the first thermobond adhesive layer, and the second thermosetadhesive layer is adjacent the second thermobond adhesive layer;simultaneously fusing and creating a permanent bond between the firstthermoset adhesive layer to the first material layer and firstthermobond adhesive layer; the first thermobond adhesive layer to thefirst thermoset adhesive layer and the second material layer; the secondthermobond adhesive layer to the second material layer and the secondthermoset adhesive layer; and the second thermoset adhesive layer to thesecond thermobond adhesive layer and the third material layer;

creating a permanently bonded stack; and cutting the permanently bondedstack into individual card forms.

A layered card comprising a first material layer having a first side anda second side; a second material layer having a first side and a secondside; a third material layer having a first side and a second side; afirst thermoset adhesive layer applied to one of the first side or thesecond side of the first material layer; a second thermoset adhesivelayer applied to one of the first side or the second side of the thirdmaterial layer; a first thermobond adhesive layer applied to the firstside of the second material layer and adjacent the first thermosetadhesive layer; and a second thermobond adhesive layer applied to thesecond side of the second material layer and adjacent the secondthermoset adhesive layer.

In a further aspect, the present disclosure may provide a layered cardcomprising a first material layer having a first and second side; asecond material layer having a first and second side; a third materiallayer having a first and second side; a first thermoset adhesive layerapplied to one of the first or second side of the first material layer;a second thermoset adhesive layer applied to one of the first or secondside of the third material layer; a first thermobond adhesive layerapplied to the first side of the second material layer and adjacent thefirst thermoset adhesive layer; a second thermobond adhesive layerapplied to the second side of the second material layer and adjacent thesecond thermoset adhesive layer; and one or more security devices withinthe card.

In yet another aspect, the present disclosure may provide a layered cardcomprising a first material layer having a first side and a second side;a second material layer having a first side and a second side; a thirdmaterial layer having a first side and a second side; a first thermosetadhesive layer applied to one of the first side and the second side ofthe first material layer; a second thermoset adhesive layer applied toone of the first side and the second side of the third material layer; afirst thermobond adhesive layer applied to the first side of the secondmaterial layer and adjacent the first thermoset adhesive layer; a secondthermobond adhesive layer applied to the second side of the secondmaterial layer and adjacent the second thermoset adhesive layer; and oneor more tagents within the card.

In accordance with another aspect, the present disclosure may provide amethod of building a layered card with tagents comprising stacking afirst sheet stock comprising a first material layer and a firstthermoset adhesive layer on top of a second sheet stock comprising afirst thermobond adhesive layer, a second material layer, and a secondthermobond adhesive layer; wherein the first thermoset adhesive layer isadjacent the first thermobond adhesive layer; positioning tagents in oneor more of the first thermoset adhesive layer and the first thermobondadhesive layer; stacking the first and second sheet stocks on top of athird sheet stock comprising a second thermoset adhesive layer and athird material layer, wherein the second thermobond adhesive layer isadjacent the second thermoset adhesive layer, thereby forming a layeredstack; applying a magnetic field to the layered stack to align thetagents; applying heat and pressure to the layered stack; and fusing thefirst material layer, the first thermoset adhesive layer, the firstthermobond adhesive layer, the second material layer, the secondthermobond adhesive layer, the second thermoset adhesive layer and thethird material layer together into a single card.

In yet another aspect, the invention may provide a layered cardcomprising a first material layer that is substantially planar and has afirst rate of thermal expansion and contraction; a second material layerthat is substantially planar and has a second rate of thermal expansionand contraction; wherein the second rate is different from the firstrate; and a thermal adhesive layer separating the first material layerfrom the second material layer; wherein the thermal adhesive layer bondsthe first material layer and the second material layer together andpermits the first material layer and the second material layer to expandand contract independently of each other while remaining substantiallyplanar and parallel to each other.

In a further aspect, the present disclosure may provide a method ofbonding a layered card comprising placing a planar first material layer,having a first rate of thermal expansion and contraction, on top of athermal adhesive layer; placing the first material layer and the thermaladhesive layer on top of a planar second material layer, wherein thesecond material layer has a second rate of thermal expansion andcontraction; and the second rate is different to the first rate;creating a stack of layers in which the first material layer isseparated from the second material layer by the thermal adhesive layer;applying heat and pressure to the stack of layers; melting the thermaladhesive layer; allowing the first material layer and the secondmaterial layer to expand independently of each other while heat is beingapplied to the stack of layers; bonding the first material layer and thesecond material to each other with the thermal adhesive layer; andmaintaining a planar profile of the stack of layers. The method mayfurther include cooling the stack of layers; and allowing the firstmaterial layer and the second material layer to contract independentlyof each other while the stack is cooled. The placing of the firstmaterial layer on top of the thermal adhesive layer further comprisesplacing the first material layer on top of a thermoset adhesive layer;and placing the first material layer and thermoset adhesive layer on topof a thermobond adhesive layer; and then placing the first materiallayer, the thermoset adhesive layer, and thermobond adhesive layer ontop of the second material layer. The bonding includes bonding thethermoset adhesive layer to the first material layer; bonding thethermobond adhesive layer to the second material layer; and bonding thethermoset adhesive layer and the thermobond adhesive layer to eachother. The melting includes melting the thermoset adhesive layer andthermobond adhesive layer and forming a single combined thermal adhesivelayer. The method may further comprise forming alternating peaks andridges in the thermoset adhesive layer and the thermobond adhesivelayer; compressing the peaks and ridges upon application of heat andpressure to the stack of layers; and mixing the thermoset adhesive layerand the thermobond adhesive layer.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

A sample embodiment of the disclosure is set forth in the followingdescription, is shown in the drawings and is particularly and distinctlypointed out and set forth in the appended claims. The accompanyingdrawings, which are fully incorporated herein and constitute a part ofthe specification, illustrate various examples, methods, and otherexample embodiments of various aspects of the disclosure.

FIG. 1A is a diagrammatic top plan view showing the layering of a firstembodiment of a PRIOR ART card.

FIG. 1B is a diagrammatic top plan view showing the layering of a firsthalf and the layering of a second half of a second embodiment of a PRIORART card.

FIG. 1C is a diagrammatic top plan view showing the layering of thesecond embodiment of the PRIOR ART card, where the first half and thesecond half are bonded together.

FIG. 2 is a side elevation view of the layers of an exemplary, PRIOR ARTcard where the core, front layer, and the back layer are straight andthe edges of the various layers are aligned with each other.

FIG. 3 is a side elevation view of the layers of the exemplary PRIOR ARTcard of FIG. 2, showing an example of the misalignment of the edges ofthe core, front layer, and back layer that may result from stressesintroduced during production.

FIG. 4 is a side elevation view of the layers of the exemplary PRIOR ARTcard of FIG. 2, showing an example of the bending or curling introducedinto the card during production.

FIG. 5A is a diagrammatic top plan view of the layers that form a frontportion and a back portion of a third embodiment of a card in accordancewith the present disclosure.

FIG. 5B is a diagrammatic top plan view showing the layering of the cardof FIG. 5A, where the front portion and the back portion are bondedtogether.

FIG. 6 is a diagrammatic top plan view of the front portion of the cardof FIG. 5A.

FIG. 7 is a diagrammatic top plan view of a decorative structure of acard that may be utilized instead of a PET layer according to an aspectof the present disclosure.

FIG. 8 is a flow chart showing an exemplary process of making a productaccording to an aspect of the present disclosure.

FIG. 9 is a flow chart showing further processing of the product of theflow chart of FIG. 8.

FIG. 10 is a diagrammatic top plan view of a second embodiment of alayered card in accordance with an aspect of the present disclosure.

FIG. 11 is a diagrammatic top plan view of a front portion of the cardshown in FIG. 10.

FIG. 12 is a diagrammatic top plan view of a back portion of the cardshown in FIG. 10.

FIG. 13 is a diagrammatic top plan view of a third portion of the cardshown in FIG. 10.

FIG. 14 is a diagrammatic top plan view of an alternative front portionof the card shown in FIG. 10.

FIG. 14A is a diagrammatic top view of an adhesive layer thatincorporates tagents therein and showing the tagents being arranged by amagnet into a pattern during processing of the card structure.

FIG. 15 is a flow chart showing a process of making the secondembodiment of the card shown in FIG. 10 and according to an aspect ofthe present disclosure.

FIG. 16 is a diagrammatic side elevation view of a PRIOR ART process forfabricating a PRIOR ART card.

FIG. 17A is a diagrammatic side elevation view of a first set of stepsof a process for producing a card in accordance with an aspect of thepresent disclosure.

FIG. 17B is a diagrammatic side elevation view of a first set of stepsof a process for producing a card in accordance with an aspect of thepresent disclosure.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION

Provided herein is a method of manufacturing using Dynamic ThermalBalancing (DTB) to produce a credit card, gift card, key card(collectively “card”, “magnetic stripe card”, or “layered plastic card”)or other layered plastic object. For simplicity, we will describe theconstruction of a single credit card, but one skilled in the art wouldrecognize that the production process could be used to form otherobjects in a planar card shape or for use in building non-planar objectssuch as a plastic cup.

DTB is a technology that allows dissimilar material types to bethermally laminated together and maintain flatness, appearance, andfunctionality. It is based on the concept of matching the coefficient ofthermal expansions (CTE) of the dissimilar materials with tie layersthat may flow but stabilize giving the needed end properties and therebysignificantly reduce the amount of rejected product.

Credit cards, gift cards and other objects of a similar type aretypically produced as the combination of a number of layers of differentmaterials that are bonded together to form a single object. In thisdisclosure, FIGS. 1A to 4 illustrate PRIOR ART cards and FIGS. 5A-15illustrate cards, structures and processes in accordance with an aspectof the present disclosure.

FIGS. 1A-1C illustrate the layering of PRIOR ART cards, with a firstembodiment of a PRIOR ART card being generally indicated by thereference number 8 in FIG. 1A, and a second embodiment of a PRIOR ARTcard being generally indicated by the reference number 9 in FIGS. 1B and1C.

With reference to FIG. 1A, PRIOR ART card 8 is comprised of an outerpolyvinyl chloride (“PVC”) front layer 10, an inner PVC core 12 and anouter PVC back layer 14. Both front and back layers 10, 14 may betransparent (i.e., clear) while the core layer 12 may be translucent oropaque. Front layer 10 is located adjacent a front surface 12 a of corelayer 12 and back layer 14 is located adjacent a back surface 12 b ofcore layer 12. Indicia, such as text and/or graphics (not shown) may beprinted using standard ink on front surface 12 a or back surface 12 b ofcore layer 12, and then the clear front layer 10 or back layer 14 isapplied thereover. (The term “standard ink” is used to denote any inkthat may be used to print on PVC but which is not capable of producingspecial effects as will be described later herein.) For example,standard inks can include flexographic and lithographic inks, as well asUV cured inks. According to another aspect, standard inks may includemore modern inks and/or printing techniques such as digital ink jetprinting and laser engraving techniques.

Each layer 10-14 in PRIOR ART card 8 has its own purpose, such asproviding structural support, protection, or to receive indicia thereon.In order to help PRIOR ART card 8 maintain its planar shape, card 8 mustbe fabricated from layers 10, 14 that are arranged symmetrically aboutcore layer 12. The symmetry of layers 10, 12, 14 needs to be maintainedso that card 8 will not tend to bend or curl. Ideally, front layer 12,core layer 12, and back layer 14 will all be of generally the same shapeand size, and all three layers will expand or contract substantiallyidentically. The symmetry is obtained by utilizing layers 10, 14 thathave substantially similar properties and thickness. When layers 10, 12,14 are of similar materials and the card 8 is constructed symmetricallyabout core layer 12, there tends to be less stress or relative movementbetween the layers, reducing bending and pitting errors in the cards 8.

FIGS. 1B and 1C show a second embodiment of a PRIOR ART card generallyindicated at 9. Card 9, like card 8, is of a symmetrical types ofconstruction. Card 9 includes a first half 9A and a second half 9B.First half 9A comprises a front layer 10, half of a split core layer 18a, and a PET layer 16 a located between front layer 10 and split corelayer 18 a. Second half 9B comprises a back layer 14, half of a splitcore layer 18 b, and a PET layer 16 b located between back layer 14 andsplit core layer 18 b. Front layer 10 and back layer 14 may be comprisedof a clear or transparent PVC. The front surface of PET layer 16 a(i.e., the surface adjacent front layer 10) may include printing,decorative designs, may be metalized, may include holograms, micrograms,images, or the like. The front surface of PET LAYER 16 a is covered withthe clear PVC front layer 10. The back surface of PET layer 16 b (i.e.,the surface adjacent back layer 14) may be over-printed and is coveredwith the clear PVC back layer 14.

When first half 9A and second half 9B are bonded (FIG. 1C), front layer10 and the PET layer 16 a are symmetrical with back layer 14 and PETlayer 16 b about core layer 18 a, 18 b. The mirrored or symmetricalconstruction can help reduce the tendency for pitting or tiny cracks todevelop in the surfaces of front layer 10 and/or back layer 14 of card 9(i.e., the symmetrical construction reduces the tendency to develop an“orange peel” surface). The use of symmetry also aids in reducing thetendency of the card 9 to become non-planar.

If the layers that are to be joined together to form PRIOR ART card 8 orPRIOR ART card 9 are too dissimilar with respect to the materials usedfor the various layers, then the layers of card 8 or 9 may expand andcontract at different rates. The difference in expansion or contractionrates may destroy the desired flatness and/or appearance of the endproduct. FIGS. 2-4 illustrate scenarios where stresses and bending areintroduced into a card or a portion of a card because of relativevariations in expansion or contraction rates between the various layersof the card.

FIG. 2 shows a first layer 10, a second layer 20, and a third layer 12.Layers 10, 20, 12 may be representative of any three layers that areformed into a card using a hydraulic press on any other similar method.If all three layers 10, 20, 12 expand or contract at similar rates, thenthe card structure so produced is substantially flat, and the opposedends of the three layers will be substantially aligned with each otheras is illustrated in FIG. 2.

FIG. 3 shows a situation where one or more of the first layer 10, secondlayer 20, and third layer 12 expand or contract at different ratesand/or to different degrees. For example, if first layer 10 is PVC andthird layer 12 is PET, the PET layer is known to cool at a differentrate and to shrink slightly in the process. FIG. 3 shows that the firstlayer 10 has expanded relative to second layer 20 and third layer 12, oralternatively, second layer 20 and third layer 12 have contractedrelative to first layer 10. The result may be that while the cardstructure still has a generally flat appearance, the ends of the threelayers are not aligned with each other, i.e., the ends are not in thesame plane. The end result is a card 15 that is less aestheticallypleasing than the one shown in FIG. 2.

FIG. 4 shows an instance where the rates or degrees of expansion orcontraction between the three layers 10, 20, 12 are so different thatthe top and bottom ends of the card structure have been drawn inwardlytoward each other. The card structure is bent or curved and is no longerflat. Bending or curving may occur, for example, if the first layer 10expands relative to the third layer 12 and is thereby placed understress, or if third layer 12 contracts relative to first layer 10, alsoputting the card under stress. Furthermore, if the first layer 10 orthird layer 12 is transparent, any pitting resulting from any off-gasproduced in the manufacturing process may be visible and give an “orangepeel” look to the card structure. If the first layer 10 or third layer12 is directly damaged by this off-gas, the card may have a roughtexture as well.

PRIOR ART cards, such as cards 8 and 9 are typically manufactured fromsheet stock which is produced and shipped to card manufacturers in flatsheets. This process will be described in greater detail later herein.

FIG. 5A shows front portion of card 11 that is comprised of first layer10, second layer 22 a, third layer 16, a fourth layer 22 b and a splitcore layer 18 a. The back portion of card 11 is comprised of a splitcore layer 18 b and a layer 14. When front portion and back portion areassembled into card 11 (as shown in FIG. 5B), first layer 10 forms thefront layer of the card 11 and layer 14 forms that back layer of thecard 11. As is evident from FIG. 5A, the front portion, and the backportion are not identical in structure. The front portion comprises fourlayers in addition to split core layer 18 a while the back portioncomprises a single layer in addition to split core layer 18 b. Card 11is therefore not symmetrical about core layer 18 a, 18 b.

First layer 10 of the front portion may be a transparent PVC layer,third layer 16 may be a PET layer, split core layers 18 a, 18 b may beopaque PVC, and layer 14 may be a transparent PVC layer. One of thefeatures of card 11 is that the second layer 22 a and fourth layer 22 bmay be free flowing copolymer layers. The copolymer layer 22 a separatesthe PVC of first layer 10 from the PET of third layer 16. The copolymerlayer 22 b separates the PVC of split core layer 18 a from the PET ofthird layer 16. The copolymer in second and fourth layers 22 a, 22 b maythermally balance between two differently expanding/contractingmaterials (i.e., the PVC and PET) that are located on either side of thecopolymer layer. These copolymer “primer” or “thermal balance” layers 22a, 22 b may absorb the differences in expansion and contraction ratesand degrees between two dissimilar layers without causing cracking,bending or pitting in the associated layers. The copolymer layers areself-leveling and may “reset” into position when the heating/coolingprocesses utilized in the production of the front portion or of card 11has ended. Specifically, these copolymer layers 22 a, 22 b can be fluidwhen heated and set to a solid structure when cooled below apredetermined temperature. The thermal balance layers 22 a, 22 b alsophysically isolate the PVC and PET layers from each other.

FIG. 6 shows the front portion of card 11, generally indicated by thereference number 13. Front portion 13, in some instances, may not bebonded to the back portion (i.e., split core layer 18 b and layer 14)and may be used on its own as a card. FIG. 6 shows printing of graphicsand text 23 and also shows an antenna or microchip 24 incorporated intofront portion 13.

FIG. 7 shows a decorative structure 26 that may be utilized in a card 11instead of the third layer 16, i.e., the PET layer. Alternatively,decorative structure 26 may comprise an additional layer or series oflayers in a card such as card 11. Decorative structure 26 may have alayer of PET 28 that comprises a core layer. PET layer 28 may have adecorative layer 30 applied thereto. Decorative layer 30 may comprisemetal, aluminum, a hologram, logo, brushed metal, vapor deposition metallayer, etc. The decorative layer 30 may applied in such a way (such asby vapor deposition) and in such an amount so as to appear as a completelayer, but may include microscopic gaps. The microscopic gaps may assistin preventing the decorative layer from blocking or reflecting signalsan antenna or microchip 24 transmits or receives. In other words, themicroscopic gaps may reduce the likelihood that the antenna signal willbe attenuated. The presence of these gaps may therefore increase theeffective range of the card so that the card may be used as a proximityform of payment instead of having to be swiped or having the chip endinserted into a payment device. In other words, providing microscopicgaps in the decorative layer 30 may make the card more usable for a“tap” type of transaction.

Previously known cards that were manufactured with a metal layer over anantenna suffered the drawback that the antenna signal was attenuated tothe point that many PRIOR ART cards could not effectively be used in aproximity payment method. It should also be noted that the bonding ofthe thermoset and thermobond adhesive layers also leaves space withincard 300 through which the antenna signal may travel. When the variouslayers of card 300 are glued together using the thermoset and thermobondadhesives, just enough adhesive is utilized to keep the adjacent layerstogether and then they coalesce when the layers are put into a hydraulicpress.

A first layer 32 a may be applied above the decorative layer 30 and asecond layer 32 b may be applied below PET layer 28. Layers 32 a, 32 bmay comprise a thermoplastic copolymer, such as Ethylene Ethyl Acrylate(“EEA”). This, in effect, may result in PET layer 28 with decorativelayer 30 being encapsulated between the two copolymer layers 32 a, 32 b.According to one aspect, each copolymer layer 32 a, 32 b may have athickness of about 0.5 to 0.6 mm. According to another aspect, eachcopolymer layer 32 a, 32 b may be approximately 1 mm in thickness.

The present disclosure may therefore provide a card with a copolymer,such as a thermoplastic, with one non-limiting example being EthyleneEthyl Acrylate Copolymer (“EEA”), between two disparate layers to allowthe layers to move independently of each other during production whilestill forming a planar/non-distorted card. The present disclosure mayalso provide a flexible polymer between two adjacent layers to allow thepolymer to prevent distortion between the two adjacent layers as theythermally expand or contract during production of a card or other suchobject.

According to one aspect, each copolymer layer 32 a, 32 b may be formedof EEA in a matrix of ethylene provided as 15% EEA and 85% low densitypolyethylene (“LOPE”). However, any other suitable copolymers ofethylene may be used. Additionally, polyolefins may also be used forlayers 32 a, 32 b. A suitable polyolefin may be polypropylene.Alternatively, Ethylene Acrylic Acid (EAA) or d-ethylene vinyl acetate(EVA) may be substituted for the EEA.

One feature of the copolymer layers 32 a, 32 b are that they may bond topolar substrates, to metals, to ester groups, to vinyl groups, etc. ThePET layer 28 may therefore be replaced with a layer of a differentmaterial such as metal. Such a metal layer may directly incorporate thefeatures of the decorative layer 30 (and therefore the decorative layer30 illustrated in FIG. 7 may be omitted from the structure).

By completely isolating the PET layer 28 utilizing the copolymer layers32 a, 32 b, the variation in expansion and contraction of any PVClayer(s) (e.g. 10, 14) relative to the PET layer 28 may be fullyabsorbed and compensated for by the copolymer layers 32 a, 32 b.Further, according to one aspect, EEA may be used as the copolymer inlayers 32 a, 32 b because it is a thermal plastic and is malleableenough to move and flow when different expansion and contraction rateproducts are located on either side of the EEA layer. The EEA may act asa primer or thermal barrier to provide a buffer between the plastics oneither side of the EEA layer 32 a, 32 b and will tend to not transferany movement forces from one side of the EEA layer to the other duringheating or cooling of the card structure. This isolation of the twoopposite sides of the EEA around the PET layer 28 also prevents pittingby “filling in” any voids as the product cools again so that lookingthrough a clear PVC layer, such as first layer 10, no roughness in thelayer is observed.

During production of a card, however, a roll of PET may be utilizedinstead of flat sheet stock. The PET may have a semicrystalline materialand may be transparent or opaque and white depending on its structureand particle size. If PET has a particle size of less than 500 nm ittends to be transparent; if the particle size is up to a few micrometersthen the PET tends to be opaque and white. The production of card 13(FIG. 6) will be described hereafter except that the decorativestructure 26 is utilized instead of PET layer 16. The creation of cardstock with a PET core 28, a decorative layer 30, two copolymer layers 32a, 32 b, two adhesive copolymer layers 22 a, 22 b, a clear PVC coverlayer 10, and PVC layer 18 may have the steps shown in the flow chart ofFIG. 8 and is further referenced herein as process or method 100. Thefirst step 102 in process 100 is to provide the PET core 28 material,which is provided as a roll of PET. Second, as the PET core 28 materialis unrolled, a decorative layer 30 is applied to the PET core 28 as step104. Then, a copolymer layer 32 a is applied over the decorated layer 30in step 106. The application of the copolymer layer 32 a may be achievedby an extrusion process, but is not limited to such. After the copolymerlayer 32 a is applied, a cooling drum cools a first side of thestructure, indicated as step 108 in the process. The next step in theprocess 100 is to then to apply a copolymer layer 32 b to the side ofthe PET core 28 opposite to that upon which decorative layer 30 has beenapplied. This is followed by step 112 which comprises cooling the secondcopolymer layer 32 b with a cooling drum. At this point in theproduction process, the result of method 100 is the stock decorativestructure 26 shown in FIG. 7.

The next step 114 in process 100 comprises applying an adhesivecopolymer layer 22 to the decorative structure 26 and over copolymerlayers 32 a and 32 b. Step 116 is to then laminate the decorativestructure 26 with a clear PVC layer (not shown) through a laminating dipsection of the process and then to wind the laminated product back intoa roll (Step 118). The clear PVC layer which is used in the laminationstep 116 differs from the PVC front layer 10 and/or from the PVC backlayer 14 as these layers will be applied during a finishing process 200shown in FIG. 9 and discussed below. This roll produced through steps102 to 118 is now considered a pre-laminated (“PreLAM”) roll that willbe supplied to a card manufacture for finishing.

The use of EEA as the copolymer layers 32 a, 32 b makes it possible tofabricate the PreLAM as a roll. If the decorative structure 26 wasfabricated without using EEA as the copolymer layers 32 a, 32 b, thenthe PreLAM might not be able to be formed into a roll and the PreLAMmight have to be shipped a sheet. PreLAM's without EEA may have to beformed as sheets in order to reduce the tendency of the structure tocurl and develop a roll set (i.e., a curvature that is difficult toovercome) when the PreLAM is cut into cards. The softer EEA as acopolymer layer 32 allows the cards to more easily go from a roll formto a flat planar form that is required for the cards.

FIG. 9 is a flow chart that illustrates a process or method 200 offinishing a card in accordance with an aspect of the disclosure. Thisprocess 200 may be representative of a process performed by a cardmanufacturer and may vary slightly depending on the type of card beingfabricated (e.g. credit card vs gift card vs loyalty card vs ID card,etc. . . . ). Minor deviations from the representative finishing process200 shown herein to account for the desired end product are consideredas normal and part of the overall scope of the disclosure herein.

The finishing process 200 may begin with the PreLAM roll produced instep 118 of process 100 described above. The first step (step 202) infinishing process 200 is to ship, deliver, or to otherwise provide aroll of PreLAM to a card manufacturer. In some instances, the producerof the PreLAM may also be the end card manufacturer, but it is notrequired that these be the same person/entity. The PreLAM is consideredraw stock at this point and is made up of the decorative structure 26with the adhesive layer and laminated clear PVC layer thereover. ThePreLAM is considered raw because it is ready to be individualized andcut into individual cards and to be provided with objects such as namesof account holders or card holders, account numbers, ID information,banking information, and the like.

The next step 204 in the finishing process 200 is to print graphicsand/or text to the top of the PreLAM directly on PVC layer that wasapplied in step 116. Next, the PreLAM may be die cut to provide an areato receive an antenna and/or chip 24 thereon. The provision of theantenna and/or chip 24 occurs later in the process. The die cut isindicated as step 206. The next step requires a second PVC core sheet,that will ultimately form second core layer 18 b, be bonded with a clearPVC layer 14. This PVC core sheet that will form layer 18 b is providedand graphics and/or text may be printed thereon and this is collectivelyindicated as step 208. Since step 208 involves a sheet separate from thePreLAM, the step may be performed separately and/or simultaneously withother steps in this process 200.

Next, in step 210, the layers to assemble into the final card form arecollated. According to one embodiment, the layers to collate are a clearPVC front layer 10, the PreLAM, the antenna and/or chip 24 that is to beinserted into the card, the second PVC sheet from step 206, and a clearPVC back layer 14.

The layers collated in step 210 may then be inserted into and compressedby a hydraulic press or the like. Heat generated during the pressingprocess causes the flow stabilizing copolymer layers 32 a, 32 b, e.g.,the EEA layers, to act to isolate the printed back core layer and thePET decorated structure from each other so that the card remains planar(i.e., flat). The heat also causes the translucent layers of copolymerbecome clear and unclouded. The pressing of the collated layers isindicated as step 212 of process 200. The thermoplastic copolymer layers32 a, 32 b also help to absorb any relative changes in the PVC and PETlayers and therefore the end product remains flat and intact afterhydraulic pressing.

The sheet of printed and bonded stock produced in step 212 may then cutinto individual cards in step 214. Step 216 which follows step 214, mayinclude embossing the cards to provide raised letters, numbers, and/orgraphics on the card. By way of non-limiting examples, the embossing mayimprint the card with the name of the cardholder, the card's expirationdate, account numbers, etc. During step 216, the card may also have amagnetic strip and/or any logos and/or holograms applied thereto.

Process 200 allows for card construction that does not need to besymmetrical or mirrored since the copolymer layers 32 a, 32 b allows forthe PET and PVC layers within the card to move independently of eachother. In other words, the copolymers allow the PET and PVC layerswithin the card to contract or expand at different rates and todifferent degrees independent of each other during heating and coolingsteps of the process 200. The back portion of the card 11 may thereforebe simplified instead of having to mirror the construction of the frontportion thereof.

With reference to FIGS. 10-14, an alternative card design is shown whichmay further streamline the card building process and may create a betterquality and more aesthetically pleasing end product. Specifically, thenew card, generally indicated as 300 in FIG. 10, may have a seven layerdesign. The seven layers includes a clear PVC cover layer 302, a firstthermoset adhesive layer 304, a first thermobond adhesive layer 306, aprinted PET layer 308, a second thermobond adhesive layer 310, a secondthermoset adhesive layer 312, and a PVC core layer 314.

Suitable materials to use as the first thermoset adhesive layer 304 andsecond thermoset adhesive layer 312 can generally be any polyurethanereactive (PUR) adhesive, including those that are water-based,solvent-based, or solvent-less. Such PUR adhesive systems are producedand/or commercially available from companies such as The Dow ChemicalCompany (DOW), CoimGroup (COIM), and/or Henkel AG & Company, KGaA(HENKEL). According to another aspect, other suitable thermoplasticadhesives may be EEA based copolymers, such as those produced by and/orcommercially available from DOW.

According to one aspect, EEA copolymers may be used for the thermosetadhesive layers 304, 312 due to their properties relative to otherlayers within card 300. Specifically EEA has a melting temperature of210° F. (approximately 98.9° C.) which is suitably high to prevent theEEA from flowing too rapidly in the liquid state and EEA further doesnot react with or degrade the PVC layers 302, 314. One example of aparticular EEA copolymer suitable for use as thermoset adhesive layers304, 312 is AMPLIFY™ EA 100 Functional Polymer produced by and/orcommercially available from DOW.

According to one aspect, first thermobond adhesive layer 306 and secondthermobond adhesive layer 310 may be a bonding and leveling polymer.Suitable materials to use as the first thermobond adhesive layer 306 andsecond thermobond adhesive layer 310 include Novacote SF-783-A PU withco-reactant CA-379 PU (Novacote), produced by and/or commerciallyavailable from COIM. While other suitable copolymers exist, Novacoteprovides a suitable laminate for printed or unprinted, metalized, and/ortransparent structures consisting of PET, amongst others.

According to one aspect, the layers of card 300, specifically thethermoset adhesive layers 304, 312 and the thermobond adhesive layers306, 310, are arranged in the presented order with thermoset layers 304,312 adjacent PVC layers 302, 314 on one side and adjacent thermobondadhesive layers 306, 310 on an opposite side to maximize the flatness ofthe final card 300. Specifically, the layers may be arranged accordingto the melting temperature of each material, moving from materials withhigher melting temperatures to materials with lower melting temperaturesto maximize the absorption of any relative changes in the PVC and PETlayers during hydraulic pressing. Accordingly, the layers are arrangedto maintain the thermoset adhesive layers 304, 312 adjacent the PVClayers 302, 314 and the thermobond adhesive layers 306, 310 adjacent thePET layer 308.

With reference to FIGS. 10-14, card 300 (FIG. 10) may be constructed inthree separate parts, namely, a front portion 300 a (FIG. 11), a backportion 300 b (FIG. 12), and a middle portion 300 c (FIG. 13). Frontportion 300 a comprises the clear PVC cover 302 and the first thermosetadhesive layer 304 (FIG. 11). Middle portion 300 b comprises the printedPET layer 308 with first thermobond adhesive layer 306 on one side andsecond thermobond adhesive layer 310 on the other side (FIG. 12). Middleportion 300 c can further include a deposition layer or embossed layerbetween the PET layer 308 and the first thermobond adhesive layer 306,similar to decorative layer 30 from card 13. Back portion 300 ccomprises the PVC core layer 314 combined with second thermoset adhesivelayer 312.

Much like process 100, the construction of card 300 may includeproducing each separate portion 300 a, 300 b, 300 c to be produced inlarge quantities as separate sheet stocks (with front portion 300 arepresenting a first sheet stock, middle portion 300 b representing asecond sheet stock, and back portion 300 c representing a third sheetstock). These sheet stocks may be fabricated by extruding or otherwiseapplying the adhesive layers 304, 306, 310, and 312 to the associatedPVC layers 302, 314 and/or PET layer 308. During the finishing of card300 (discussed below as process 400), front portion 300 a, middleportion 300 b, and back portion 300 c may be assembled together to formthe completed card 300 that is illustrated in FIG. 10.

FIG. 14 illustrates the introduction of first thermoset layer 304 andthermobond layer 306 between PVC cover layer 302 and the PET layer 308during assembly of card 300. The introduction of first thermoset layer304 and thermobond layer 306 between cover layer 302 and layer 308creates a bond that provides substantially 100% coverage on both the PVClayer 302 and the PET layer 308. Specifically, when the first thermosetand first thermobond layers 304, 306 are applied one on top of theother, they may create a series of peaks 316 and valleys 318 where theadhesives intersect. These peaks 316 and valleys 318 may be created byembossing the first thermobond layer 306 with a pattern of peaks 316 andvalley 318 which are then filled in by the marriage of the firstthermoset adhesive layer 304 and the first thermobond adhesive layer306. This arrangement may create a geometric matrix of bonding pointswithin the first thermoset adhesive layer 304 and first thermobondadhesive layer 306 which may allow for expansion and/or contraction ofthe card layers during manufacturing. The peaks 316 and valleys 318 mayreach each of the PVC and PET layers 302, 308 and thereby provide alight bond that may hold the layers in position relative to each otherduring construction of the card 300. Then, when heat and pressure areapplied during the finishing process 400, as discussed below, the peaks316 and valleys 318 will be compressed and both the first thermoset andfirst thermobond 304, 306 adhesives will flow into all the interstitialspaces between the PVC and PET layers 302, 308 providing full coveragetherebetween. This arrangement results in a very tight bond that securesthe layers of the card 300 together. Although described as peaks 316 andvalleys 318, it will be understood that other geometric patterns can beapplied, without limitation.

Card 300 may further include security measures embedded within thelayers of card 300. The first of these security measures may be RFIDchips and/or antennas (such as antenna/chip 24 shown in FIG. 6). Theinclusion of thermoset and thermobond adhesives, and the clarityimparted from the bonds between the thermoset and thermobond adhesives,makes it possible for embedded RFID chips or antennas to operate well,i.e., signals are transferred readily through the layers. As indicatedearlier herein, previously known cards and methods of production haveresulted in cards having a signal strength for embedded chips/antennasin a range of from about 8-14 MHz, with an industry standard ofapproximately 13.56 MHz. Signal strength is measured as the power of thesignal detected/detectable within the card. If the signal is not 10 MHzor less, PRIOR ART cards tend to block the signal to and/or from thatantenna and the card is not useable. The clarity provided by thethermoset/thermobond combination of card 300 allows for a signalstrength of 1-2 MHz, which translates into a very strong signal that isgenerally unaffected by the card 300 itself. A lower number for signalstrength is desired; the strength signifies the speed at which thesignal moves through the vapor deposition of the card.

Additional security measures often found on or in layered cards,especially credit cards and/or identification cards, are holograms orother three dimensional graphics. Often these measures are included tohelp detect counterfeit cards and/or to detect post-productionmodification of cards. PRIOR ART practices have involved printing thesesecurity features directly on exterior surface of the PRIOR ART cards.Printing security features on the exterior surface may, of course, allowthose security features to be scraped off or be materially altered.

The layered design of cards 300, on the other hand, particularly theinclusion of a PET layer 308 with the thermoset/thermobond adhesivelayers 304, 306, 310, and 312, substantially prevents such physicalalterations. At a minimum, the structure of cards 300 renders it obviousthat alterations were made to the card. As discussed herein, printingmay be done directly on the PET layer 308, with or without overprintingon the outer PVC layer 302. If security printing, such as holograms,micrograms, or three dimensional graphics, are printed directly on thePET layer 308, alterations would require the removal of the PVC layer302 as well as the breakage of the extremely strong bond between thethermoset adhesive 304 and thermobond adhesive 308. Further, as thethermoset/thermobond combination results in a card with exceptionalclarity, the printed PET layer 308 is highly visible, making thesesecurity measures equally visible, highly effective, and tamperresistant.

Another type of security measure that is enabled through the use of thethermoset and thermobond adhesive layers, 304, 306 and 310, 312 is theuse of tangent lines. These lines may be fabricated from metallic,semi-metallic, or other reflective materials 305 (FIG. 14A) that areferromagnetic or have ferromagnetic properties. During production,alignment of the tangent lines, known as tagents 307, may beaccomplished through use of a strong B-field, or magnetic fieldgenerated by a magnet 309. (FIG. 14A shows a horseshoe magnet but itwill be understood that any type of magnet may be utilized to organizethe tagents 305 into a pattern.) The magnetic field produced by magnet309 may be used to orient the tagents 305 directly within the adhesivelayers, 304, 306, 310, 312, and/or directly on the PET layer 308. FIG.14A shows tagents 305 in first thermobond adhesive layer 306. Thetagents 305 are initially located randomly within layer 306. Afterexposure to a magnetic field produced by any type of magnet 309, thetagents 305 are organized into a pattern 307 within layer 306. Thetagents 305 are exposed to the magnetic field prior to subjecting thestacked first portion 300 a, second portion 300 b, and third portion 300c to heat and pressure to bond the various layers to each other. Thepattern of the tagents is fixed during bonding and may subsequently beused as a security measure/identifier. It will be understood that whileFIG. 14A shows a circular pattern 307 of tagents 305, the tagents 305may be arranged in any desired pattern within any of the aforementionedlayers of card 300. The tagents are only visible under anelectromagnetic field (EMF) light and may be arranged to reflect the EMFlight in specific directions and/or patterns. This type of securityinvolves placing these tagents within the layers of the card itself.Specifically, the tagents may be printed or otherwise placed directly onthe PET layer 308 and oriented prior to applying the thermobond adhesivelayers 306, 310. Alternatively, the tagents may be disposed within thethermoset and/or thermobond adhesive layers, 304, 306 and 310, 312 andmagnetically oriented prior to pressing the layers in step 422 ofprocess 400, discussed below. Once the card has been processedcompletely, EMF light passing through the layers of the card may flowonto the tagents, and the tagents reflect the light back through thecard layers in a specific pattern or direction.

According to one aspect, tagents may be non-planar and may create animage that appears to be offset when viewed at different angles.According to another aspect, the tagents may have curved facets that maybe oriented in such a manner as to create a spherical lens or sphericalreflective surfaces on the facets that may allow the reflections toappear as three-dimensional images within the card. Light may be allowedto flow into the material of the card 300 and onto a back side of thefacets of the tagents to light them up. If the light is shown throughthe adhesive, the facets tend to light up even better. The thermobondadhesives tend to melt into the facets of the tagents and the adhesivehelps the facets to light up well because of the clarity of the adhesiveand because of the low conductivity of the adhesive.

According to one aspect, the tagents may have a length and/or a heightthat is less than the total thickness of the layer in which they areplaced. This may allow the placement of the tagents to vary in depthwithin the layer to further enhance or provide three dimensional effectsto the card. By way of one non-limiting example, the tagents may have alength of approximately 2 microns while the adhesive layers 304, 306 and310, 312 may have a total thickness of approximately 20 microns. Thus,the tagents may be arranged at any depth within that 20 micronthickness. The specific placement may then give the tagents a depth offield in their reflective properties.

According to another aspect, an effect similar to the inclusion oftagents may involve the use of vapor deposition of metal onto the PETlayer 308 and/or in the adhesive layers 304, 306 and 310, 312. The metalvapor may be applied in a variety of different thicknesses such that animage may be created using the deposited metal layer. According to thisaspect, vapor deposition may be applied on the back side of the PETlayer 308 or in adhesive layers 310 and/or 312. This process may beperformed to protect any printing, graphics, holograms and any othersecurity measures or three-dimensional images that have been applied tothe opposite or front side of PET layer 308.

According to another aspect, the thermoset and thermobond adhesivelayers 304, 306, 310, and 312, may include holograms within the adhesivelayers themselves. These holograms may be formed within the adhesive asa security measure, with the holograms being protected similar toholograms and/or security measures placed on the PET layer 308. Further,these holograms may be used in conjunction with tagents and/or othersecurity features to give an additional layer of counterfeit or illegalmodification protection.

Card 300 imparts a number of advantages over the current designs in thatthe use of both a thermoset adhesive and a thermobond adhesive joinsdissimilar materials, such as the dissimilar PVC layers 302, 314 and PETlayer 308. This joining of dissimilar materials may be accomplishedwithout pitting, cracking, peeling, bending, curling, or other flawsbeing created within card 300 because of the different cooling rates andtransition temperatures of the different materials used in card 300.Thermoset adhesives do not tend to produce an off-gas and therefore thetendency for an “orange-peel” effect in the card 300 is greatly reduced.Additionally, the PET layer 308 may be printed with text, graphics,special effects, or any other desired embellishments prior to adding thethermobond adhesive layers 306, 310. During production of card 300,there may be a vapor deposition of metal and this deposition occurssufficiently rapidly that the material does not tend to coalesce. Inother words, the vapor deposition does not fully cover the surface uponwhich it is deposited. Spaces tend to be left between the “dots” ofmetal that are deposited and this enables signals from any antennaprovided in card 300 to get through the deposited metal layer.

The outer PVC layers, both cover 302 and core 308 may also be printed orembellished as desired utilizing existing printing technology andmaterials. This may eliminate the need for additional layers beingprovided in a card specifically for printing thereon. This may furtherresult in reduced cost of manufacture as older inks that were notpreviously suitable for printing due to smearing, marring, or othererrors introduced during fabrication may now be utilized within card300. Thermoset and thermobond adhesive layers 304, 306, 310, and 312prevent smearing and marring of these inks during card production.

An additional advantage is that the PET layer 308 may be printed whilethe PVC cover layer 302 may be overprinted (i.e. printed with identicalmarkings that line up with the printing on the PET layer). This processmay create better quality and more aesthetically pleasing text,graphics, and/or images on the card 300. Finally, the thermoset andthermobond adhesive layers 304, 306, 310, and 312 work in concert tocreate very tight bonds to the PVC, PET and to each other, whileimparting little to no resistance to light waves or radio frequencywaves passing through these layers. This in turn allows for securityfeatures to be embedded or otherwise placed deep within the card itself,thereby protecting them from removal or alteration.

Although card has been described herein as including layers of PVCand/or PET, it will be understood that card 300 may, alternatively, befabricated with other materials, including other similar or dissimilarlayers, without deviation from the scope described herein. According toone aspect, the core of card 300 may be metal or metal foil.

FIG. 15 shows a flow chart illustrating a process 400 for the creationand finishing of card 300 from raw materials. First, in step 402, aclear PVC stock (which will later become cover layer 302), a PET stock(which later becomes PET layer 308), and PVC core stock (which laterbecomes PVC core layer 314), are provided.

The next three steps, 404, 406, and 408, may be completed separatelyand/or simultaneously as each step involves only one of the previouslymentioned stock products. Step 404 involves coating the clear PVC stockon one side with the thermoset adhesive layer 304, creating frontportion 300 a of card 300. Step 406 involves coating the PET on bothsides with the first and second thermobond adhesive layers 306, 310,creating middle portion 300 b of card 300. Step 408 involves coating PVCcore on one side with the second thermoset adhesive layer 312, creatingback portion 300 c of card 300. If an optional step of printing on thePET stock is to be performed, it would be performed prior to the coatingstep 406. This optional and intermediate printing step may also includethe printing and/or installation of security measures, as discussedabove.

According to one aspect, the coating of the PET layer 308 with thethermobond adhesive layers 306, 310 that occurs during step 406 givesthe PET layer 308 a frosted or clouded appearance. This is due toocclusions within the adhesive that will later be eliminated with theaddition of heat in the later pressing step (i.e., step 422 that isdiscussed below).

Following the coating steps 404, 406, and 408, each of the front portion300 a, middle portion 300 b, and back portion 300 c is cooled in steps410, 412, and 414, respectively to set the adhesive layers 304, 306,310, and 312. According to one aspect, the cooling steps 410, 412, and414 may be performed by one or more cooling drums.

Once each front portion 300 a, back portion 300 b, and middle portion300 c is cooled, optional steps 411 (for front portion 300 a) and 415(for back portion 300 c) may be performed. Optional steps 411 and 415include printing directly on PVC cover layer 302 or PVC core layer 314,respectively, any text, graphics, or images as desired. If it isdesirous for middle portion 300 b to be printed, optional printing step405 would have been previously performed prior to applying thethermobond adhesive layers 306, 310, therefore middle portion 300 bmoves directly from the cooling step 412 to next step 416.

Once the adhesive layers are fully set in cooling steps 410, 412, and414, and sections 300 a and/or 300 c are printed as desired, each offront portion 300 a, back portion 300 b, and middle portion 300 c, (i.e.first, second, and third sheet stocks) may be coiled into separate rollsthat may then be stored or prepared for shipping to a card manufacturer.The coiling and storing/preparing for shipment is indicated as step 416.

Alternatively, if the stock producer is also a manufacturer of the endcards 300, the individual rolls of sheet stock may immediately proceedinto the finishing process (indicated as process 418), skipping coilingstep 416.

The first step in finishing process 418, indicated as step 420, is tocollate the sections in the appropriate order, with front portion 300 alayered atop middle portion 300 b, which is in turn placed atop backportion 300 c. If front portion 300 a is overprinted with identicalmarkings as PET layer 308, it is important to ensure proper placementand alignment of front portion 300 a over middle portion 300 b prior tomoving to step 422.

In step 422, the collated layers are placed into a press where heat andpressure cause the thermoset and thermobond adhesive layers 304, 306 tocoalesce into a clear, tightly bonded layer. Similarly, the thermosetand thermobond adhesive layers 310, 312 will coalesce into a clear,tightly bonded layer. The bonds in these tightly bonded layers may haveas much as ten times the strength of the bonds created in PRIOR ARTcards by previously known manufacturing processes. The bonds created inthe present process give card 300 significant strength and durability.Effectively, the thermoset adhesive 304, 312 bonds the PVC 302, 314, thethermobond adhesive 306, 310 bonds to the PET, and then the thermobondand the thermoset adhesives 304, 306 and 310, 312 will interstitiallybond to each other. This effectively allows the assembly of dissimilarlayers of PET and PVC into single layered card 300.

Finally, in step 424, individual cards 300 may be cut from the stock andembossed with information, such as account numbers, cardholder names,expiration dates, and magnetic strips applied, etc., as desired.

Added benefits of producing card 300 according to processes 400 and 418include that the bond created by the combination of both thermoset andthermobond adhesives is both stronger than in PRIOR ART products.Furthermore, the bonds created in card 300 result in a very clear bondlayer that has clarity of a magnitude that is far greater than what waspossible in the PRIOR ART. This is because thermoset adhesives aregenerally known to be hazy or milky in appearance, but the mixing ofthermoset and thermobond adhesives in the manner described herein inprocess 400 clears this haze and gives the bonded layer a very clean andclear finish.

If additional security measures, such as tagents, metal vapordeposition, holograms, or the like are desired, these additionalfeatures may be placed, as described above, prior to or during optionalprinting steps 405, 411, and/or 415; prior to or during the applicationof adhesive layers 304, 306, 310, and 312 in steps 404, 406, and 408; orprior to collating layers in step 420 of processes 400 or 418.

According to one aspect, the known properties of PET provide additionalbenefits in the construction of layered card 300. Specifically, PET hasa very high melting point, so when included in the pressing step of themethods described herein, the PET layers do not melt. Instead, the otherlayers melt around the PET layers and the melting of the other materialsfills in any spaces within or between the layers of material. Thisfurther aids in making the outer layers of card 300 very clear. Theprocess also makes it possible to use PVC as the outermost layers of thecards 300 which ensures that the card 300 may be easily printed uponboth during the finishing process, and after the finishing process iscompleted. Additionally, incorporating PET into card 300 ensures thatthe card is able to withstand higher pressures when in the press duringprocessing. These pressures may be in the order of up to about 35Newtons. PRIOR ART cards were not able to withstand pressures of morethan about 7 Newtons up to about 11 Newtons. The increase in possiblepressures in card 300 helps to ensure that the thermoset and thermobondadhesives melt more completely, thereby ensuring complete coverage ofthe surrounding layers with these adhesives and ensuring bonding betweenadjacent layers in the cards.

FIG. 16 is a diagrammatic side elevation view of a simplified PRIOR ARTprocess for fabricating a PRIOR ART card 8 or 9 as shown in FIGS. 1-4and described earlier herein. The process will be described withreference to the production of card 9 in a first plant 500 and in asecond plant 502. In this process, the material of a first half 9A (FIG.1B) is unwound off a roll 504 and the material of a second half 9B areunwound off a roll 506. The material of the first half 9A is overlaidover the material of the second half 9B and the two materials are passedthrough a press 508 where they are bonded together to form a combinedmaterial 510. Material 510 is a layer of card stock that is then movedin the direction of arrow “A” and passes through a cutting device 512.The cutting device 512 cuts the material 510 into a plurality ofindividual planar sheets of card stock represented as sheets 510 a, 510b. Each sheet is a planar sheet and these planar sheets of card stockare assembled into a stack 514 on a pallet 516. A plurality of pallets516 are shipped from first plant 502 to second plant 504 via some typeof transportation device 518. When the pallets 514 arrive at the secondplant 504, each planar sheet 510 a, 510 b etc. of card stock isindividually removed from the stack 514 of card stock sheets on thepallet 516 and individual cards 9 are separated from each sheet of cardstock such as sheet 510 a. It will be understood that the entire processmay occur in the first plant 502 and the transportation device 518 andsecond plant 504 may be omitted from the process. Additionally,individual sheets 510 a, 510 b etc. may not be stacked onto pallets 516but may be sent directly through to the final step of the process whereindividual cards 9 are cut from the sheets 510 a, 510 b. In otherinstances, individual cards may simply be cut from the material 510after it exits the press 508. The materials used in card 8 or 9 and themanner of how the cards 8 or 9 are produced and finished has beendescribed earlier in this document.

FIGS. 17A and 17B are diagrammatic side elevation views of a process forproducing cards 300 in accordance with FIGS. 10 through 14 as has beendiscussed earlier herein. In this process and in a first plant 600, afirst layer 302 and a second layer 304 are assembled into a first cardstock material 300 a. The first card stock material 300 a is allowed toset. In particular, the first card stock material 300 a is set by beingcooled by cooling drums, fans or another other suitable coolingmechanisms or equipment. The cooling of first card stock material 300 ais indicated by the arrows “C”. The first card stock material 300 a isthen rolled onto a roll 602.

In a second plant 604, a third layer 306, a fourth layer 308, and afifth layer 310 are assembled into a second card stock material 300 b.The second card stock material 300 b is allowed to set. In particular,the second card stock material 300 b is set by being cooled by coolingdrums, fans or another other suitable cooling mechanisms or equipment.The cooling of second card stock material 300 b is indicated by thearrows “C”. The second card stock material 300 b is then rolled onto aroll 606.

In a third plant 608, a sixth layer 312 and a seventh layer 314 areassembled into a third card stock material 300 c. The third card stockmaterial 300 c is allowed to set. In particular, the third card stockmaterial 300 c is set by being cooled by cooling drums, fans or anotherother suitable cooling mechanisms or equipment. The cooling of thirdcard stock material 300 c is indicated by the arrows “C”. The third cardstock material 300 c is then rolled onto a roll 610.

The materials that form the layers 302, 304, 306, 308, 310, 312 and 314have been described earlier herein and therefore will not be discussedfurther with respect to the process illustrated in FIGS. 17A and 17B.

It will be understood that one or more of the first card stock material300 a, second card stock material 300 b, and third card stock material300 c may be fabricated in a single plant, 602 for example.Alternatively, two of these card stock materials 300 a, 300 b, and 300 cmay be fabricated in one of the plants 602, 604, 608 and the remainingone of the card stock materials 300 a, 300 b, 300 c may be fabricated inanother one of the plants.

If, as illustrated in FIG. 17A, all three of the card stock materials300 a, 300 b, 300 c is fabricated in a separate plant, then thesematerials may be shipped out of the associated plants by transportationvehicles, such as 612, 614, and 616 and may be taken to a fourth plant618 (FIG. 17B).

In the fourth plant 618, the first card stock material 300 a is unrolledfrom roll 602, the second card stock material 300 b is unrolled fromroll 604, and the third card stock material 300 c is unrolled from roll308. First card stock material 300 a is positioned to overlay secondcard stock material 300 b, and second card stock material 300 b ispositioned to overlay third card stock material 300 c. The overlaidthree card stock materials 300 a, 300 b, 300 c are passed through ahydraulic press 620 where pressure and heat are applied to the cardstock materials, thereby bonding the same into a fourth card stockmaterial 300 d. The fourth card stock material 300 d is set by beingcooled by cooling drums, fans or another other suitable coolingmechanisms or equipment. The cooling of fourth card stock material 300 dis indicated by the arrows “C” in FIG. 17B. The fourth card stockmaterial 300 d is then rolled onto a roll 624. One or more rolls 624 arethen shipped out of plant 618 by transportation vehicle 626 and aretaken to a fifth plant 628. In the fifth plant 628 the fourth card stockmaterial 300 d is unrolled from roll 624 and individual cards 300 areseparated from the fourth card stock material 300 d. It should beunderstood that the fourth card stock material 300 d assumes a planarshape when unrolled from roll 624 and therefore may readily and easilybe cut into cards 300.

It will be understood that cooling “C” of the first, second, third, andfourth card stocks 300 a, 300 b, 300 c, 300 d may be undertaken in orderto set the thermoset adhesives and the thermobond adhesives that formpart of these card stocks.

It will be understood that the plants 618 and 628 may be one and thesame location, in which case the transportation vehicle 626 may beomitted. Furthermore, instead of fourth card stock material 300 d beingwound onto roll 624, the fourth card stock material 300 d may be movedinto a final stage of the process where individual cards 300 may be cutfrom the fourth card stock material 300 d after cooling “C” thereof hasoccurred.

It will further be understood that additional finishing processing ofthe fourth card stock 300 d may be undertaken as has been describedearlier herein with the reference to process 400.

While various inventive embodiments have been described and illustratedherein, those of ordinary skill in the art will readily envision avariety of other means and/or structures for performing the functionand/or obtaining the results and/or one or more of the advantagesdescribed herein, and each of such variations and/or modifications isdeemed to be within the scope of the inventive embodiments describedherein. More generally, those skilled in the art will readily appreciatethat all parameters, dimensions, materials, and configurations describedherein are meant to be exemplary and that the actual parameters,dimensions, materials, and/or configurations will depend upon thespecific application or applications for which the inventive teachingsis/are used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, many equivalentsto the specific inventive embodiments described herein. It is,therefore, to be understood that the foregoing embodiments are presentedby way of example only and that, within the scope of the appended claimsand equivalents thereto, inventive embodiments may be practicedotherwise than as specifically described and claimed. Inventiveembodiments of the present disclosure are directed to each individualfeature, system, article, material, kit, and/or method described herein.In addition, any combination of two or more such features, systems,articles, materials, kits, and/or methods, if such features, systems,articles, materials, kits, and/or methods are not mutually inconsistent,is included within the inventive scope of the present disclosure.

One skilled in the art would appreciate that the concept of athermoplastic coplanar isolation layer between two dissimilar plasticlayers could be used in the construction of objects other than cards.For example, the sheets could be rolled to make a tube or a cup, such asa printed logo cup for a football stadium cup with a team's logo, etc.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including,” “carrying,” “having,”“containing,” “involving,” “holding,” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto. Only the transitional phrases “comprising” and “comprisingessentially of” shall be closed or semi-closed transitional phrases,respectively, as set forth in the United States Patent Office Manual ofPatent Examining Procedures.

An embodiment is an implementation or example of the present disclosure.Reference in the specification to “an embodiment,” “one embodiment,”“some embodiments,” “one particular embodiment,” or “other embodiments,”or the like, means that a particular feature, structure, orcharacteristic described in connection with the embodiments is includedin at least some embodiments, but not necessarily all embodiments, ofthe invention. The various appearances “an embodiment,” “oneembodiment,” “some embodiments,” “one particular embodiment,” or “otherembodiments,” or the like, are not necessarily all referring to the sameembodiments.

Additionally, any method of performing the present disclosure may occurin a sequence different than those described herein. Accordingly, nosequence of the method should be read as a limitation unless explicitlystated. It is recognizable that performing some of the steps of themethod in a different order could achieve a similar result.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the PRIOR ART because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of various embodiments of thedisclosure are examples and the disclosure is not limited to the exactdetails shown or described.

What is claimed:
 1. A method of building a layered card comprising thesteps of: placing a first sheet stock further comprising a firstmaterial layer and a first thermoset adhesive layer on top of a secondsheet stock further comprising a first thermobond adhesive layer, asecond material layer, and a second thermobond adhesive layer; placingthe first and second sheet stock on top of a third sheet stock furthercomprising a second thermoset adhesive layer and a third material layer;forming a single stack of sheet stock wherein the first thermosetadhesive layer is adjacent the first thermobond adhesive layer, and thesecond thermoset adhesive layer is adjacent the second thermobondadhesive layer; simultaneously fusing the first thermoset adhesive layerto the first material layer and first thermobond adhesive layer; thefirst thermobond adhesive layer to the first thermoset adhesive layerand the second material layer; the second thermobond adhesive layer tothe second material layer and the second thermoset adhesive layer; andthe second thermoset adhesive layer to the second thermobond adhesivelayer and the third material layer; thereby creating a permanent bondbetween each layer; and cutting the permanently bonded stack intoindividual card forms.
 2. The method of claim 1 further comprising thestep of printing one of text, graphics, images, or a combination thereofon the first material of the first sheet stock wherein the step ofprinting on the first material layer is performed before assembling thesheet stock into a single stack.
 3. The method of claim 1 furthercomprising the step of printing one of text, graphics, images, or acombination thereof on the third material layer of the third sheet stockwherein the step of printing on the third material layer is performedbefore assembling the sheet stock into a single stack.
 4. The method ofclaim 1 further comprising the step of embossing the individual cardforms with account numbers, cardholder names, bank information, or acombination thereof.
 5. The method of claim 1 wherein the first materiallayer and third material layer are polyvinyl chloride (PVC) and thesecond material layer is polyethylene terephthalate (PET).
 6. A layeredcard comprising: a first material layer having a first and second side;a second material layer having a first and second side; a third materiallayer having a first and second side; a first thermoset adhesive layerapplied to one of the first or second side of the first material layer;a second thermoset adhesive layer applied to one of the first or secondside of the third material layer; a first thermobond adhesive layerapplied to the first side of the second material layer and adjacent thefirst thermoset adhesive layer; and a second thermobond adhesive layerapplied to the second side of the second material layer and adjacent thesecond thermoset adhesive layer.
 7. The layered card of claim 6 whereinthe first thermobond adhesive layer and first thermoset adhesive layerare fused into a single first combined adhesive layer throughapplication of heat and pressure applied to the card.
 8. The layeredcard of claim 7 wherein the second thermobond adhesive layer and secondthermoset adhesive layer are fused into a single second combinedadhesive layer through application of heat and pressure applied to thecard
 9. The layered card of claim 8 wherein the third material layerforms a base layer and the first material layer, second material layer,first and second thermoset adhesive layers, and the first and secondthermobond adhesive layers are all above the base layer.
 10. The layeredcard of claim 9 wherein the base layer further comprises the back faceof the card.
 11. The layered card of claim 9 further comprising an RFIDchip and antenna.
 12. The layered card of claim 6 wherein the first andthird material layers are PVC and the second material layer is PET. 13.The layered card of claim 6 wherein the second material layer furthercomprises printed text, graphics, images, or a combination thereof onthe first side.
 14. The layered card of claim 13 wherein the firstmaterial layer further comprises printed text, graphics, images, or acombination thereof on the side opposite the first thermoset adhesivelayer.
 15. The layered card of claim 14 wherein the third material layerfurther comprises printed text, graphics, images, or a combinationthereof on the side opposite the second thermoset adhesive layer. 16.The layered card of claim 14 wherein the printed text, graphics, images,or a combination thereof on the first material layer is identical to theprinted text, graphics, images, or a combination thereof on the secondmaterial layer.
 17. The layered card of claim 15 wherein the identicalprinted text, graphics, images, or a combination thereof on the firstand second material layers are aligned such that they appear as a singleprinting.
 18. The layered card of claim 6 further comprising embossedtext, graphics, images, or a combination thereof.